1. A training & project report
Submitted in partially fulfillment of the requirement for the
degree of
Bachelor Of Technology
In
Electronics and Communication Engineering
By
Akshay Dhaka(131300018)
E.C. Third year
From- CENTRAL ELECTRONICS LTD.

2. SUMMER TRAINING REPORT
(During June-July,2015)
AT
CENTRAL ELECTRONICS LIMITED
Submitted in partial fulfillment for the award of the Degree
IN
BACHELOR OF TECHNOLOGY
(Electronics & Communication Engineering)
GLA UNIVERSITY
MATHURA
UNDER THE GUIDANCE OF
SHRI P.C. AWASTHI (AGM)
SMT. SAVITRI KASHYAP (CM-SPD QC)

3. CONTENTS
1. Certificate
2. Acknowledgement
3. Company Profile
(a) Introduction
(b) The organization – CEL
(c) Departments at CEL
(d) Products of CEL
(e) Nation’s Pioneer & World leader in SPV
(f) Innovative Electronic System
(g) Quality Policy of CEL
4. Universal Axle Counter
(a) Introduction
(b) Flow chart of manufacturing
(c) Principle of working
(d) Brief description
(e) Specifications
5. Description of various modules of Axle Counter System
6. Other products of CEL
(a) SPV products
(b) Cathodic Protection System
(c) Ferrite Products
7. New Products
8. Self Evaluation

4. ACKNOWLEDGEMENT
I am highly thankful to Mr. P.C. Awasthi (CMD) and Mrs. Savitri Kashyap (CM SPD QC) for
providing me the opportunity to undergo the practical training in the Systems Production
Division (SPD) at Central Electronics Limited. They guided me from time to time and gave me
dynamic ideas and suggestions by which I am able to complete my training successfully.
I am also thankful to manager of various departments who guided me about the works &
processing that are being done in their respective departments.
I am also thankful to all those employees at CEL who classified my doubts and confusions during
my training period at the firm. It was a greatly satisfying experience to work in such an excellent
professional organization where the process of learning is never ending.
I also want to thank all the other directly or indirectly associated people who helped me in
completing my practical training with great success
AKSHAY DHAKA
ECE-B1
GLA UNIVERSITY
MATHURA

5. CENTRAL ELECTRONICS LIMITED
COMPANY PROFILE

6. INTRODUCTION
Central Electronics Limited is a public sector Enterprise under the Department of Scientificand
Industrial Research (DSIR), Ministry of Science & Technology, Government of India. It was
established on 26th
June, 1974 with an objective to commercially exploitthe indigenous
technologies developedby national laboratories and R & D institutionsin the country. CEL is one
of the rare companies which utilizedthe homegrown technologies during all these years of its
existence
CEL has developed a number of products for the first time in the country through its own R&D
efforts and in close association with the premier National & International laboratories including
Defense Laboratories. In recognition of all these efforts, CEL has been awarded a number of
times with prestigious awards including “NATIONAL AWARD for R&D by DSIR”.
CEL is pioneerin the country in the fieldof Solar Photovoltaic (SPV) and it has developedstate
of the art technology with its own R&D efforts. Its solar products have been qualifiedto
International Standards EC503/IEC1215 by the European Commission, joint Research center,
and ISPRA, ITALY.
CEL, pioneer in the fieldof Railways Safety & Signaling, has been identifiedas a major
indigenous agency for design an development of modern electronic signaling and safety
equipment by Indian Railways. The equipment manufactured in CEL finds extreme usage in
Railways in the form of Axle Counter, Axle Counter Block System and Train Approach Warning
devices. CEL’s Digital Axle Counter is approved as per European CENELEC safety level SIL-4 by
RDSO(Research Design and Standard Organization of Indian Railways )as an approved source in
part-1 for various railway safety and signaling equipments for more than 25 years
CEL has developed a number of critical components for strategic application and is supplying
these items to Defense.

7. ORGANISATION STRUCTUREOF CEL
CHAIRMAN &
MANAGING DIRECTOR
GENERAL GENERAL
MANAGER MANAGER
(PROJECT
MANAGEMENT)
Jt. GENERAL Jt. GENERAL
MANAGER MANAGER
(FINANCE) (MATERIALS
MANAGEMENT)
EXECUTIVE AGM
DIRECTOR (QUALITY
ASSURANCE)
GENERAL Jt. GENERAL AGM
MANAGER MANAGER (FERRITE)
(SYSTEMS)
GENERAL Jt. GENERAL Jt.GM
MANAGER MANAGER (CERAMICS)

8. DEPARTMENTS AT CENTRAL ELECTRONICS LIMITED
1. SOLAR PHOTO VOLTAIC
· SOLAR PHOTOVOLTAIC CELLS
· SOLAR PHOTOVOLTAIC MODULES
· SOLAR PHOTO VOLTAIC SYSTEMS
i. APPLICATION RURALS
ii. APPLICATION INDUSTRIALS
2. STRATEGIC ELECTRONIC
· RAILWAYS ELECTRONICS
i. SINGLE SECTION DIGITAL AXLE COUNTER
ii. MULTI SECTION DIGITAL AXLE COUNTER
iii. TRAIN ACTUATED WARNING DEVICES
iv. UNIVERSAL AXLE COUNTERS
· MICROVE ELECTRONICS
i. PHASE SHIFTERS
3. OTHERS
· CATHODIC PROTECTIONS
· CERAMICS

9. Products from CEL
The organization manufactures differentproducts that can be classified according to the
divisionsof CEL as follows:
Solar Photovoltaic Group :
· Solar Cells/Modules
· Solar Lantern
· Street Light System
· Home Light System
· Water Pumping System
Electronic Systems Group :
· Single / Multiple Entry / Exit Axle counters
· Universal Axle counters
· Block proving system
· Railway Level Crossing Warning system
· Solid State Interlocking System for Railways
· Cathodic Protection system
· Very Small Aperture Terminal (VSAT)
· Electronic Switching Equipments
Components Group :
· Different types of ferrite cores like Pot, RM, E, U, I, etc
· Piezoelectric transducer elements
· Special Bearings used in Heavy Water Plants
· Microwave Ferrite Phase shifters
· Direction Finding Systems
· Frequency / Phase Correlators

10. NATION’SPIONEER & WORLD LEADER IN SOLAR PHOTOVOLTAIC
In an era of growing energy needs and rising concern for environment, solar energy, the
abundant and pollution free non-conventional energy source, offers the best alternative
solution.
CEL, with its commitment to harness the solar energy, has opened up new vistas in the fieldof
solar photovoltaics. CEL is the poignant and the largest producer of solar photovoltaics.
Backed by an integrated production facility,CEL has made accumulative supply of over 1.5 lacs
SPV systems (20 MW) spread over 28 differenttypes, covering both rural and industrial
applications. The company has not only givena fillipto the Indian SPV market but also exported
products to Indonesia, Bhutan, Bangladesh, Egypt, Cuba, Nepal, Mali, Columbia and Costa
Rica.
CEL has successfully transferred technology for manufacturing SPV Modules and Systems to
Rajasthan Electronics & Instruments Ltd. India in 1985 and very recently to Scientific Studies
and Research Center (SSRC), Syria in May 1997. This is the first case of SPV Technology Export
from the Developing World.
CEL’s SPV Modules conform to the international specifications – JPL Block V and IEC
specification no. CEI / IEC 61215. CEL SPV Modules were certifiedby European Solar Test
Installations (ESTI), JRC, ISPRA, Italy.

11. INNOVATIVE ELECTRONIC SYSTEMS
Signaling and SafetySystems for the Indian Railways
CEL is the pioneer Public Sector Company supplying Railway Signaling and Safety equipments
to Indian Railways.
CEL continually identifiesnewrequirements of the Railways and develops / manufactures the
same in association with Research, Design and Standards Organization (RDSO) and Railway
Board.
The Company is currently engaged in developmentof Digital Axle Counter in association with
RDSO and Department of Scientific Industrial Research (DSIR).
The product is undergoing extensive field trials in different zones of Indian Railways and
software validation is under progress. The product is expected to be deployed in Indian
Railway’s Signaling network in large numbers by the end of year 2002.
Cathodic Protection Systems
CEL suppliesAutomatic Cathodic Protection Systems for the protection of oil / gas pipelinesto
organizations like Indian Oil Corporation, ONGC and GAIL.
The Company suppliesdifferent types of Cathodic Protection Systems operating with solar
photovoltaic or thermoelectric power sources or operating on grid supply.

12. QUALITYPOLICY
The complete manufacturing operation, marketing and installation services of
the company are certified under ISO 9002: 1994. The company has enunciated
the following quality policy to meet customer needs and expectations through
supply of quality products and services.
“CEL is committed to strive for leadership in the product marketed by the way
of continuous improvements in the quality of its products and services and
meeting the consumers needs in time and every time at a competitive price.
These shall be achieved through continuous upgrading of technology and
process improvement by involving all the employees, vendors, dealers and
customers.
Quality is our basic business principle.”

13. UNIVERSAL AXLE COUNTER
FOR RAILWAYS

14. INTRODUCTION
Axle counters were developed as a substitute for track circuiting. Initiallyaxle counters were
imported from Germany to gain experience and to evaluate their suitability for adoption on
Indian Railways. Having gained acceptability for introduction on a wide scale on Indian Railways,
it was considered to take up indigenous developmentof axle counters, which was taken up in
collaboration with IIT, Delhi and DOE. Two models of axle counters known as single entry/exit
axle counter and multi entry/exitaxle counters emerged and after extensive laboratory and
fieldtrails under various conditions, the design was finalizedand commercialized through
private sector as well as public sector.
Based on the feedback from field,a new axle counter has been developedby RDSO, known as
“UNIVERSAL AXLE COUNTER”.
NEED FORAXLE COUNTERS:
The track circuits are considered as the vital components of signaling system to achieve safety
of train operations. Various Accident Enquiry Committees have recommended to bring more
and more tracks under track circuiting to safeguard against reception of trains on occupied
lines.The track circuiting could not achieve desired progress due to virtual scarcity of wooden
sleepers,prohibitive cost and environmental consciousness in the country and the world at
large. Availabilityof concrete sleepershave solved the problem to some extent but track
circuiting on loop lines,points and crossings still suffers for want of adequate supply and
insertion of concrete sleepers.
Advantages:
The advantages of Axle Counter over a conventional track circuit are:
(i) It does not require wooden sleepers (where concrete sleepers are not available)
except for short track circuits to suppress the counts due to movement of insulated
trolleys.
(ii) An Axle Counter System can cover a very long section of up to 15 km as compared to
750 meters of maximum length of operation of conventional track circuit.
(iii) It does not get affected either by flooding of track or poor maintenance of tracks
unlike track circuits, which is highly susceptible to these conditions.
(iv) It does not require insulatingjoints, thus, rails can be continuously welded.This
reduces track maintenance cost, lower wear and tear of tracks and vehiclesand to
increase traveling comfort.

15. Applications:
Axle counters are finding more and more uses on modern safety signaling systems in the
railways. These are being used presentlyfor the followingapplications:
(i) Monitoring of berthing tracks in station areas and yards.
(ii) Monitoring of point zones in station areas and yards.
(iii) Automatic signaling systems.
(iv) Block section monitoring (between stations) through axle counters using
multiplexers with cable or radio communication (18 GHz).
(v) Level crossing warning system.

16. FLOW CHART FORMANUFACTURINGPROCESSOF AXLECOUNTER
Fabrication
Raw Materials
CABINET FABRICATION
INSPECTION
Rejected Accepted
PAINTING
Mechanical
Components
MECHANICAL FITTING
CABINET WIRING
Electronic Components
PCB
COMPONENT MOUNTING
Rejected
INSPECTION
Accepted
WAVE SOLDERING
CLEANING
RE -WORK
STATION
INSPECTION
Rejected Accepted
CARD TESTING
LACQUERING
SYSTEM INTEGRATION
SYSTEM TESTING
INSPECTION
SHIPMENT

17. PRINCIPLEOF OPERATION
Signal aspect for train movement is controlled based on clear or occupied status of the track
section. If a train occupies the track section, signal at the entry point of the section is made RED
and the next train is stopped from entering into the section. When the track section is clear the
signal is made GREEN and the train is allowed to proceed into the section.
The clear or occupied condition of the track section is decided by Axle Counter by counting the
number of axles of train at entry and exit points of the section. The axle counter compares the
IN and OUT counts and in case of count equality TRACK CLEAR signal is given. In all other
conditions TRACK OCCUPIED signal is given.
Signal Signal
R1 R2 Railway Track R3 R4
T1 T2 T3 T4
Entry Point Track Section Exit Point
EJB 1 EJB 2
Signal Control
Relay Output
Cable
EVALUATOR Cable
BLOCK DIAGRAM OF AXLE COUNTER INSTALLATION

18. BRIEF DESCRIPTION
The Axle Counter is an electronic device and the complete system consists of:
(i) Track mounting and trackside equipment.
(ii) Transmission media between trackside equipment and central evaluator.
(iii) Central evaluator with EV relays and SUP relays as its output.
(iv) Reset box.
(v) Line verification box.
Track mountings and track side equipments:
The track mounting equipment consists of a pair of transmitter and receiver coils housed in
specially designedhousings, which are fixedto flange of a rail section by means of suitable rail
clamps using bolts and nuts. Each detection point has two sets of such tracks devicesmounted
on same rail with a fixed stagger betweenthem. The two transmitter coils of a detection point
are connected in series to 5 kHz oscillators housed in electronic junction box which is installed
in a location box by the side of the track. The output of two receiver coils of a detection point
serve as inputs to two receivers amplifiers housed in the same electronic junction box through
cables which are part of the track mounting equipment. Electronic junction box is powered by
24 V DC supply.
Transmission media between trackside equipment and central evaluator:
The connection between trackside equipment and central evaluator is made using balanced twin
twisted quad cables of specification IRS: TC/41/90. The output of electronic junction box and
input of central evaluator are matched for an impedance of about 180 ohms at 5 kHz.
There is attenuation of signal from electronic junction box to central evaluator, which limits the
length of the cable. Other media such as optic fiber and wireless system may also be used in
place of cable by incorporating appropriate interfacing equipment at transmitting and receiving
ends.

19. Central Evaluator with EV relay and SUP relay as its output:
The signals received from electronic junction boxes are processed in the central evaluator first by
analog circuits and then by digital circuits to produce suitable output in terms of picking up or
dropping of EV and SUP relays. The DIPs generated by wheels as they pass over the track devices
installed at detection points, after they get processed, generate count pulses in a fail safe
manner.
These pulses are identifiedas ‘IN COUNTS’ or ‘OUT COUNTS’ depending on the direction of
movement of vehiclesover the monitored section. The counts are also displayedthrough the 7-
segment display on the front panel of the evaluator. The display unit is useful in fault localization
and initial and periodical adjustments.
The evaluator is provided with its own power supply unit known as DC – DC converter mounted
in the same rack and requires 24 V DC supply for its operation. The output of the EV and SUP
relays is used to indicate “TRACK CLEARED” or “TRACK OCCUPIED” conditions.
Reset Box:
This equipment is installed in the station master’s room to enable resetting of central evaluator
in case of failure of system after observing prescribed procedure. The reset unit consists of a
RESET key (which gets actuated after inserting, turning and pressing), the counter and 3 LED
indications (Red, Yellow and Green). This unit requires 24 V DC supply for its operation. This unit
functions in conjunction with the line verification box.
Line Verification Box:
This box is required to be kept near monitored track portion outside Station Master’s (SM) office
for achieving co-operative feature. This is a box consisting of a lock with a key fixedinside.The
lock gets actuated only when the key is inserted, turned and pressed. Whenever there is a failure
of axle counter, SM will depute his ASM/Switchman to verifywhether the track section
controlled by axle counter is clear or not. ASM/Switchman, after verification of the track, will
report to SM if track is found clear who in turn will handover the key of line verificationbox for
operation.

20. TYPE OF SYSTEMS:
There are four types of system used in the Indian Railways. They are named below:
(i) One Device (1-D) System.
(ii) Two Devices (2-D) System.
(iii) Three Devices (3-D) System.
(iv) Four Devices (4-D) System.
1-D System:
In this system, there is a common detection point at entry and exitpoint of monitored section.
This system is useful for monitoring the berthing track of terminal yard. A train after passing the
detection point generates pulses equal to axlesin it and these pulses are counted and stored by
the evaluator as ‘IN COUNTS’.
At the time of exitof train, the same detection point will be encountered and it generates the
same number of pulses as that during the entry. These pulses are counted and recorded as ‘OUT
COUNTS’ by the evaluator. When the IN COUNTS and OUT COUNTS are equal, the system gives
a “Track clear” indication otherwise it givesthe “Track occupied” indication.
2-D System:
The principle of working of this system is similar to 1-D System except that in this system there
are two detection points, one at each end of the monitored section. This system is useful for
providing track circuiting on berthing track.
3-D System:
In this system, there are three detection points. The principle of working of this system is similar
to 2-D system. This system is useful for providing track circuitry on points, crossings and sidings.
4-D System:
In this system, there are four detection points. The principle of working of this system is similar
to 2-D system. The system is useful for providing track circuiting on branch lines,sidings and
points and diamond crossings. The design of 4-D system is such that it can be converted into a
2-D system or a 3-D system and vice–versa.

21. SPECIFICATIONS
Universal Axle CounterSystem mainly comprises of following equipments:
1. Rack, ACS-55/56/57 -- (Common type for all models) 1 No.
2. Evaluator -- EV – 542 / 543 / 544 1 No.
3. DC-DC converter -- (inside Evaluator only as 10th
Card) 1 No.
4. Electronic Junction -- for 2D system (ACS-55-2D) 2 Nos.
Box, JB-533 -- for 3D system (ACS-56-3D) 3 Nos.
-- for 4D system (ACS-57-4D) 4 Nos.
5. Reset box -- RB – 257B 1 No.
6. Track Device -- for a 2D system (ACS-55-2D) 2 Nos.
Assembly, -- for a 3D system (ACS-56-3D) 3 Nos.
TR – 556 -- for a 4D system (ACS-57-4D) 4 Nos.
7. Line verification box -- LV – 261 1 No.
PARAMETER SPECIFICATIONS
1. No. of Detection Points
ACS-55 / 56 / 57 2 / 3 / 4
2. Maximum Train Speed 200 Kmph
3. Counting Capacity 1023
4. Max. Line Attenuation (over cable) 20 dB
5. Signal Input (5 KHz) sinusoidal Min. 150 mv.rms
Max. 1500 mv.rms
6. Relay Drive Voltage for 1000 ohm
Shelf type 4F / 4B relay or Q Style > 10 V
Plug in Relay 1000 ohm, 4F / 4B

22. Power Requirement:
Powers required by various units are as follows:
DC – DC Converter 1.5 Amp max.
24 V (-10% to +20%)
Evaluator 24 V 1.5 Amps
(21.6 – 28.8 V DC)
Junction Box 24 V < 250 mA
(21.6 – 28.8 V DC)
Reset Box 24 V 500 mA
(21.6 – 28.8 V DC) (only when reset key is
pressed)
Environmental Conditions:
Relative Humidity 95 % - 98%
Non-Condensing
Temperature range:
Universal Evaluator 0 to +60 ˚C
Junction Box & Track Devices 0 to +70 ˚C

23. PHYSICALCHARACTERISTICS:
The approximate dimensionsand weights of various units of Universal Axle Counter are given
as follows:
Name of UNIT WIDTH DEPTH HEIGHT WEIGHT
(mm) (mm) (mm) (kg)
SINGLE 570 650 1065 70
RACK
DOUBLE 600 650 1460 100
EVALUATOR 482 439 310 21
JUNCTION BOX 208 280 170 5
RESET BOX 255 175 115 2.3
TRACK DEVICE 515 330 170 15
ASSEMBLY
LINE VERIFICATION BOX
150 135 80 1.20
Colour:
The rack is painted in a combination of light and dark grey colours. Evaluator, Junction box and
Reset box are also painted in the same colour combination. The track devices are painted in black
colour.

24. IDENTIFICATION:
Rack:
The identificationlabel of the rack is put at the lefthand top on the front side of the rack with
inscription.
a) For a 2D system Universal axle Counter, ACS – 55 with EV – 542 Evaluator.
b) For a 3D Universal Axle Counter System, ACS – 56 with EV – 543 Evaluator.
c) For a 4D Universal Axle Counter System, ACS – 57 with EV - 544 Evaluator.
The serial no. label is mounted on the right hand top side of the rack at the back.
Evaluator:
The label “Evaluator, EV - 542”, “EV - 543” or “EV - 544”, for a 2D, 3D or a 4D system respectively
is marked on the front side of the evaluator. The serial no. label is on the back side.
Junction Box:
On the top (front) of the Junction Box the label “JUNCTION BOX, (JB-533)” is given while the
serial no. label is on the back plate.
Reset Box:
The label “RB – 257B” is given on the front side.The Sr. No. label is on the back side.
Line Verification Box:
The label “LINE VERIFICATION BOX, LV - 261” is put on the front side and the Sr. No. label is on
the right side cover.
Track Devices:
Labels indicating the TX and RX coil of the Track Devices are given on each track transducer.
DC – DC Converter:
It is the 10th
Card Module inside the Evaluator and it is marked as “POWER SUPPLY”.

25. DESCRIPTIONOF VARIOUSMODULES OF AXLECOUNTER SYSTEM
1. EVALUATOR:
The Evaluator consists of 10 PCB modules. The interconnections between the various PCB
cards are made with the help of a motherboard. The polarization arrangement (to avoid
wrong insertion of modules) is provided on the aluminum modular sheets in each. Hence it is
important to ensure correct fitting of modular shield in each card. In the Universal Axle
Counter System manufactured by Central Electronics Limited, relevant card number has been
number punched for easy identification to ensure correct fitting of modular shields. A brief
description of each P.C. assembly is given below.
(a) Attenuator/Amplifier & Rectifier Card (Card no. 1):
This is a double sided PCB (Size:225mm X 275mm). It contains four identical channels,
each comprising of a 5 kHz high pass filter,a line matching transformer, attenuator
pads, a two stage amplifierand a full wave rectifier.The output of each channel can be
set precisely by means of a lockable shaft potentiometer mounted at the front end of
the PCB module. Typical output is 300 mV (P-P) or 105-mv rms.
(b) Attenuator/Amplifier & Rectifier Card (Card no. 2):
This is a double sided PCB (Size: 225mm X 275mm). It contains four identical channels,
each comprising of a 5 kHz high pass filter, a line matching transformer, attenuator pads,
a two stage amplifier and a full wave rectifier. The output of each channel can be set
precisely by means of a lockable shaft potentiometer mounted at the front end of the
PCB module. Typical output is 300 mV (P-P) or 105-mv rms.
For 1D and 2D Systems, there will be one such card (Card no. 1) while for 3D and 4D Systems, the
evaluator will have two nos. of such cards (Card nos. 1 & 2).
(c) Pulse Shaper Card (Card no. 3):
This is a double sided PCB (Size: 225mm X 275mm). It contains four identical channels,
each consisting of a low pass filter, a Schmitt trigger, an impulse time filter and a 10 V to 5
V level converter. The outputs of these channels are TTL compatible. In addition to above,
each channel comprises of a Trolley Suppression Circuit.
(d) Pulse Shaper Card (Card no. 4):
This is a double sided PCB (Size: 225mm X 275mm). It contains four identical channels,
each consisting of a low pass filter, a Schmitt trigger, an impulse time filter and a 10 V to 5
V level converter. The outputs of these channels are TTL compatible. In addition to above,
each channel comprises of a Trolley Suppression Circuit.

26. For 1D and 2D Systems, there will be one such card (Card no. 3) while for 3D and 4D Systems,
the evaluator will have two nos. of such cards (Card nos. 3 & 4).
(e) Logic – I (Card no. 5):
This is a double sided PCB (Size: 225mm X 275mm). This card generates ‘IN COUNTS’ and
‘OUT COUNTS’, depending upon the direction of the train movement, due to the dips
caused form the track transducers E, F, G, H. In addition to main count pulses, duplicate
INCOUNT and OUTCOUNT pulses are also generated here for supervision purpose. The ‘IN
COUNT’, ‘OUT COUNT’, ‘Duplicate In count’ and ‘Duplicate Out count’ pulses are fed
separately to different combiner gates housed in card 6 (Logic II) and thereafter fed to the
counter card (Card 7) for further processing.
As E, F, G, H channel inputs are used only in case of 3D or 4D Systems, card 5 will be used only
with the 3D and 4D Evaluators.
(f) Logic – II (Card no. 6):
This is also a double sided PCB (Size: 225mm X 275mm). This card houses the logic
circuitry to generate ‘IN COUNTS’, ‘OUT COUNTS’, ‘DUPLICATE IN COUNTS’ and
‘DUPLICATE OUT COUNTS’ due to the dips caused from channel inputs from the track
detection points A, B, C and D. It also has combiner gates, which combine the count
pulses generated from all the detection points AB, CD, EF and GH. The outputs of these
gates are fed to the counter card (Card no. 7) for counting and counts supervision.
Card 6 also has an ‘INTERROGATOR’ circuit. This generates four clock pulse trains. All
these four pulse trains are staggered in phase, with each of these pulse trains having a
phase difference of 25 µs, as compared to the subsequent one.
The interrogator ensures that even if more than one INCOUNT or more than one
OUTCOUNT are fed simultaneously from different detection point, the final count pulses
fed to the counter card get staggered and thus counts are not missed.
In addition to above, this PCB also houses the IN/OUT supervision circuits, both counter
checking each other. In case of any malfunction the system latches to failure condition.
This card also houses the 1st
OUTCOUNT inhibit circuit which ensures latching up of the
system in the event of 1st
count getting registered being an ‘OUT COUNT’ instead of an
‘IN COUNT’.
(g) Counter Comparator(Card no.7):
This is a double sided PCB (Size:225mm X 275mm). This card houses two 10 stage digital
counters-one for counting the ‘IN COUNTS’ and the other for ‘OUT COUNTS’. It also has
count super- visioncircuits, both for in counts as well as the out counts, to check the
integrity of the counters. In addition, there are two comparators; one being a duplicate

27. of the other, to compare the counts from the two counters the ‘IN COUNTER’ and the
‘OUT COUNTER’.
The outputs of the comparators are further compared with EX-OR chain to ensure integrity of
the comparators.
(h) General Supervision Card (Card no. 8):
This is a double sided PCB (Size:225mm X 275mm). It houses the followingevaluator
circuits:
(a) Comparator Supervision.
(b) A series of mono shot pulses forming a chain for static supervisioni.e. to
prove the effectivenessof a number of DC levelsof the system and a few ground
points.
(c) Pulse Shaper (Card no. 3 and 4) supervision for all the eight channels.
(d) Failure supervision.
(i) Relay Driver (Card no. 9):
This is a double sided PCB (Size:225mm X 275mm) and it houses the followingcircuits:
(i) Level detector circuits for all the 8 channel inputs to ensure the presence of
proper channel input levels.
(ii) The ‘VOLTAGE MONITOR’, which serves as, a ‘WATCH DOG’ for the +5V power
supply to the Evaluator.
(iii) Relay driver outputs for driving the EV relay and the supervisory relay.
(j) Counts Display Card :
This is a double sided PCB (Size:225mm X 275mm) containing four sevensegment LED’s for
‘IN COUNTS’ and four sevensegment LED’s for ‘OUT COUNTS’ and it can count up to 1023
counts in both the display. This card is mounted on front panel of evaluator and counts are
recorded in decimal system.
(k) EV & SUP Relay Indication LEDs:
The output of the Evaluator is used to drive two 12 Volts DC, 4F/4B shelf type relays or 12
Volts DC, Q-style 4F/4B plug-in relays which are used to indicate the track clear or track
occupied indications to control signal aspects. Two 10 mm dia. LEDs (Green and Red) have
been provided in the front side of the Axle Counter Rack in a metallic strip for locally
displaying the position of the above relays. These LEDs have to be suitably wired at the time

28. of installation as per requirements from the terminal strip connections provided at the rear
side of the Axle Counter Rack.
(l) Mother Board:
This is a double sided PCB (Size: 420 mm X 260 mm) mounted at the back of the Evaluator.
The PCB is mounted at right angles to the other 10 PC Cards and serves the purpose of
providing various interconnections between them. The female parts of the Euro Connectors
are mounted on this PCB and corresponding male parts which are mounted on the PCBs
(Cards 1 to 10) mate with them when the card modules are inserted in the unit. The mother
board also provides access, through MS Couplers, to feed various inputs like channel inputs
from the tracks, power supply and trolley protection and to feed outputs to the EV and the
Supervisory Relays kept in the rack.
(m) Reset Relay:
This is mounted at the back of the Evaluator on the motherboard. A 67DP-24-4C3 OEN Relay
is mounted on this PCB with a mounting socket. This Relay resets the System whenever
required to do so.
2. ELECTRONICJUNCTIONBOX (EJB):
The Electronic Junction Box houses PCB modules which are inter-connected through
motherboard. All the incoming / outgoing signals are terminated on the MS Couplers (7 pin)
mounted at the back of the junction box. Two types of outputs are available from the EJB.
The output of the EJB is sent to the Evaluator either through a 4 wire or a 2-wire system.
(a) 4-Wire System:
In a 4-Wire System, two pairs of under ground cable are required to send transition
signal to evaluator for counting the dips. In this system there are three PCBs consisting
of common oscillator feeding to two transmitter coils in seriesand two number of
receiver amplifiers,one for each receiver coil. The sequence of cards is- regulator and
oscillator in first position, first amplifierin second position and second amplifierin the
3rd
position from left to right.
Detail of individual cards:
CARD No. 1 :
Regulator / Oscillator Card. (Size: 200 mm X 110 mm)

29. This is a single sided PCB (Size: 200mm X 110 mm), which generates 5 KHz ±20 Hz sinusoidal
signal which is fed to the transmitter coils in series. The output voltage is 60 V ± 10% (RMS)
and current supplied is 420 mA ± 10% in the coils in series.
CARD No. 2 :
Receiver Amplifier-1.(Size: 200 mm X 110 mm)
This is a single sided PCB of size same as that of card 1 and it rejects any noise over riding in
the signal by means of a two stage tuned amplifier. The output of the receiver coil (1) is fed
to the input of the amplifier. The output of the amplifier is connected to the Evaluator and
voltage is more than 1.2 V (RMS).
CARD No. 3 :
Receiver Amplifier-2.(Size: 200 mm X 110 mm)
This card is exactly similar to card no. 2 and is used for receiver coil (2).
(b) 2-Wire System :
In 2-wire system, a 4th
card is inserted in the EJB, which converts the frequency of the second
receiver amplifiersignal to 3.5 KHz with the use of converters. Thus, 2-wire system is having
output on 2-wire and consists of 4 cards, namely the regulator / oscillator card, the receiver
amplifiercard-1, the receiver amplifiercard-2 and 4W / 2W card. This is used in block
working at Advance starters only.
The sequence of cards is:
(i) Regulator / Oscillator Card.
(ii) Receiver Amplifier Card-1.
(iii) Receiver Amplifier Card-2.
(iv) 4W / 2W Converter Card.
3. RESET BOX:
This box houses one 12 way PIRI terminal strip for terminating IN / OUT signals. The
indication LEDs of the reset box are fitted in LED holders and projected to the front for
indication. Green and Red indications are given for track clear and track occupied conditions.
The YellowLED indicates co-operative permission for resetting the Axle Counter.

30. 4. TRACK DEVICE ASSEMBLY:
The Single Rail Track Device Assemblyconsists of two transmitter and two receiver coils
assembly, which are fitted with suitable mounting arrangements on the rail camp, which in
turn is fitted to the rails. The two transmitter coils at each of the detection point are fed in
series by a 5 KHz sinusoidal signal from the junction box, which forms an electromagnetic
fieldacross the receiver coils. The receiver coil in turn generates induced voltage. The
induced voltage drops to a minimum wheneverthere is an axle between the transmitter
and the receiver coils.
(a) Track Device Transmitter:
The transmitter coil is placed in a FRP housing and it is potted in place by m-seal
compound. It is fixed on the rail clamp on the outer side of the rail. Each transmitter
coil will be provided with a 10 meter, 24 / 0.2 PVC cable.
(b) Track Device Receiver:
The receiver coil is housed in a composite Aluminum fiber glass housing and is potted
in place by the means of an m-seal compound. The receiver housing is fixed on the
base clamp on the inner side of the rail. Each receiver coil will be powered with a 10
meter, 24 / 0.2 PVC cable.
5. POWER SUPPLY:
The Power Supply, to the Evaluator is fed by a DC–DC Convertor. The various output
voltages of the DC–DC Convertor are as follows:
+ 5 V@ 5Amp. with ± 0.1% line & load regulation.
+ 5 V@ 5Amp. with ± 0.1% line & load regulation.
+ 10 V isolated @500 mA.
The DC-DC Convertor in turn derives its power from a + 24 V dc source i.e.a battery bank.
The Junction Box (JB - 531) and the Reset Box (RB – 257B) are also powered from + 24 V dc
battery bank.
All the supplieshave over current protection while 5V supply has additional crow bar
protection at 6.2 volts.

31. PRODUCTIONTESTING & TEST PROCEDURE:
The semi – conductor devices like diodes and transistors used are of high reliability type. The
other vital components like ICs mostly are the commercial grade ICs which will undergo burn in at
60°C with dc power ‘ON’ for 72 hours.
This will eliminate the failure of critical components after the assembly of the PCB.
WAVE SOLDERING:
All the PCB’s assembly will be wave soldered for good reliability and also coated with lacquer to
withstand climatic conditions.
INSPECTION:
Each unit will be examined for proper workmanship, fitness, finish and proper markings. Also
each unit will be tested thoroughly as per the test schedules mentioned in the test report before
the final shipment.

32. SPECIAL FEATURES
The Universal Axle Counter has the followingspecial features:
PCB LAYOUT:
Better PCB layouts to have supply feeding and decoupling for better noise immunity.
MOTHER BOARD:
The use of mother board gives extra noise immunity as compared to back panel wiring.
RACK:
The Evaluator is housed in a rack fabricated out of M.S. sheet. This gives good noise immunity
against electromagnetic interference.
SHIELDING:
The Rack is well shielded for better noise immunity. All the metallic frames of the rack are
interconnected to the main frame by means of 34 / 0.3 wire. Shielded cables will be used in
system, shield of which is connected to the back panel of the Evaluator.
CARD INSERTION:
Each Card along with a module is guided separately.
CARD MODULES:
Each Card is provided with a module along with the identificationlabel.
CARD POLARISATION:
Polarizing holes on the card modules and guiding pins from the Mother Board side are used to
provide card polarization to ensure correct card slotting.
MODULE TIGHTENING SCREWS AND CARD HANDLES:
Module tightening screws are provided to fix the cards along with the module in the unit
smoothly. By loosening, the cards can be removed from the unit. Two card handles are provided
on each module. The modules can be taken out with the help of these handles.
COUNTS DISPLAY:
The Counts display is given on a PCB and mounted on the front panel inside and is viewed
through display viewing plate at the front panel of the Evaluator.
EVALUATOR MARKINGS:
In each unit input /output labels,the supply, channel markings and trolley protection A / B, C / D
are marked.

33. OTHER PRODUCTS

34. OTHER PRODUCTS OF CEL
SOLAR WATER PUMPING SYSTEMS:
A Solar Photovoltaic Water Pumping System essentiallyconsists of an SPV panel or array
directly powering a water pump. Water pumped during the day can be stored in the storage
tanks for use during the night.
CEL offers SPV Water Pumping Systems for both shallow as well as deep well conditions. Such
systems have been deployed all over the country. The system has also been exported to many
developing countries.
The generated electricity from the SPV array is fed to the pump through a switch. Normally low
storage batteries are provided, as the water can be stored in the storage tanks if required.
SOLAR PHOTOVOLTAIC LIGHTING SYSTEMS:
CEL’s Solar Photovoltaic Lighting Systems are ideal sources for providing indoor/outdoor
illumination in remote and un-electrified settlements/ villages. The SPV Lighting System
essentially consists of an SPV panel battery, a charge controller and lights. The SPV panel
converts the sunlight incident on it directly to DC electricity that can be stored in the battery and
used to energize the lights when required. The charge controller prevents the overcharging and
deep discharge of the battery.
SPV INDOORLIGHTING SYSTEMS:
Two types of indoor lighting systems are available (DLS-02 and DLS-04) depending on the lighting
requirements. DLS-02 has two numbers of 9W luminous efficiency lamps with wall mounting
fittings. DLS-04 has four such lamps. Each lamp can give the output of 60-watt incandescent
lamp.
SPV OUTDOORSLIGHTING SYSTEMS:
These systems use a weather proof 18-watt or 20-watt fluorescent tube light fittings. Two models
SLS-03 and SLS-06 are available depending on hours of operation in day. Switching ON at dusk
and OFF after specified hours of operation is automatic. The SPV panel, battery and the tube-light
fittings are mounted on a 4M long pole.

35. SOLAR LANTERNS:
CEL Solar Lantern is a versatile and a reliable source of lighting. It consists of a lantern, a SPV
module and a connecting cable. The SPV module when exposed to light charges the battery in
the lantern. This stored energy in the battery is used to operate the lamp when required.
SPV MODULE :-
A number of high-grade crystalline silicon solar cells, interconnected in series
combination and hermetically sealed with a toughened glass cover, form a SPV
module.
SALIENT FEATURES :-
 ENVIRONMENTAL FRIENDLY
 PORTABLE
 RUGGED AND DEPENDABLE
 SILENT OPERATION
APPLICATIONS :-
 EMERGENCY LIGHTING SOURCE
 LIGHTING SOURCE IN REMOTE VILLAGES
 LIGHTING AT PICNIC SPOTS AND FARM HOUSES
 GARDEN LIGHTING
 LIGHTING AT MILITARY OUTPOSTS

36. MILESTONES OF SPV SYSTEMS DEVELOPMENT AT CEL
 SPV operated Radio set in Jammu & Kashmir - 1978
 SPV Irrigation Water Pumping System installed at Kalyani, West Bengal – 1979
 SPV Pumping System for drinking water near Jaipur – 1980
 SPV Community Lighting Systems installed at SOS children’s village, Leh, Ladakh, J&K –
1980
 SPV Community Television Systems installed at Kalyani, West Bengal – 1980
 Special SPV Power Pack for the first Indian scientific expedition to Antarctica – 1981
 First SPV Power System for unmanned off-shore oil well platform of ONGC – 1982
 SPV operated Diesel Dispensing Pump – 1982
 Export of SPV Water Pumping and other System – 1983
 First SPV powered stand-alone Street Lighting System in Salojipali, Andhra Pradesh –
1983
 SPV foldable modules for Everest-84 Expedition – 1984
 SPV systems for Direct Reception community TV sets of Doordarshan – 1985
 SPV Systems for Cathodic Protection of oil pipelines – 1985
 SPV systems for Vaccine Refrigeration in village Health Centers –1985
 Design and supply of first SPV Systems for very low powered unmanned TV transmitter
(VLPT) & TV Receiver Only (from INSAT) (TVRO) terminals of Doordarshan - 1986
 Supply of SPV Power System for weather monitoring, lighting and entertainment at an
Avalanche Study Station at Rohtang Pass (ALT : 3600 mtrs/12000 ft.) in the Himalayas –
1986
 SPV powered Lighting and Television System for army at Siachin (ALT : 3600 – 5500 mtrs
/ 12000 ft.) in the Himalayas – 1987
 Supply of first 2 KW power SPV Village Power Pack – 1987
 SPV systems for warning signals at Unmanned Railway Level Crossings – 1988
 SPV Rural Deep well Water Pumping Systems for National Drinking Water Mission -
1989
 SPV Power System for Rural Telecommunication transmission and switching
equipments – 1989
 Supply and installation of SPV Systems in village Hitam-ulu, Sumatra, Indonesia – 1990
 SPV Lighting Systems for Adult Education under National Literacy Mission – 1990
 Supply and installation of 6 KW Power Plant at Kariawali village in U.P. – 1990
 Supply and installation of Asia’s first 100 KW SPV Power Plant at Kalyanpur village near
Aligarh, U.P. – 1992
 10 KW Power Generator for M.S. Swaminathan Foundation at Taramani, Madras –
1993
 Supply of Foldable Lightweight SPV modules for powering Man pack Communication –
1993
 Equipments for the defense services to operate in the temperature range from –30°C to
+55°C.

37. CATHODIC PROTECTION SYSTEM
INTRODUCTION:
M/s Indian Oil Corporation Limited is presently laying 18” dia., 437 Km. long pipe line in 2
segments for augmenting the capacity of existing OD 498 Km. long Haldia-Barauni Crude Oil
pipeline from Haldia to Barauni.
Owner intends to provide permanent cathodic protection system consisting of 13 nos. of
impressed current cathodic protection station to cathodically protect the underground coated
pipeline for a design life of 35 years.
BASISIN BRIEF:
Permanent CP System has been designed for CTE coating having coating resistance of 7000 ohm /
m factor of safety as 1.3. Designed life of anode bed is 35 years and that of the CP system is 20
years.
SUMMARYOF PERMANENT CP SYSTEMS:
Designed current densityconsidered for design : 125 microA/sq. mts.
Total no. of CP stations : 13 Nos.
Total designed current for entire span : 103.8 A
Max. design current of CP station : 10A
Total no. of 22 Kg high silicone chrome anode : 250
PROJECT INFORMATION:
The Haldia – Barauni Augmentation pipeline is starting from Haldia and it terminates
approximately 473 Km. away at HBPCL near Barauni.
Coating Details:
The pipelinesshall have yard coated coal for tar coating with fiberglass reinforcement. The
coating resistance in normal soil shall be 7000 /m.

38. Depth of pipeline:
Generally the HBPCL has proposed the pipeline to be laid at minimum depth of 1 mt. from the
ground level.Depth may increase to 9 mts. or more dependingon the soil.
High silicon-chrome anode and anode beds:
The anodes shall be High Silicon Chromium cast iron, cylindrical type. Anodes shall be provided
with encapsulated heads and heat sink caps connected at top.
The technical data of the Hi-Si-Cr-Fe anodes assembly shall be as under.
 ANODE TYPE : Hi-Si-Cr-Fe Anode
 DIMENSIONS : 65 mm. Dia. & 1 mt. long
 WEIGHT : 22 Kg.
 COMPOSITION: -
Si : 4 % to 15.5 %
Mn : 0.8 %
C : 1.4 %
Cr : 4.5 %
Fe : remaining

39. NEW PRODUCTS

40. SINGLE SECTION DIGITAL AXLE COUNTER
A state-of-the-art Digital Axle Counter has been developedby CEL for track monitoring of single
section in railways.
The system is designed with:
· High frequency track coils.
· Track side electronic counting unit including vital relay drive.
The system has two detection points for monitoring either end of the section. When the train is
entering the section the wheel counts are registered and stored in the 1st
SSDAC unit. When the
train is entering the section the wheel counts are registered and stored in the 2nd
SSDAC unit.
After exchange of counts stored in both SSDAC1 and SSDAC2 units, the section is declared as
‘CLEAR’ in case the counts are equal. Otherwise the section is shown as ‘OCCUPIED’.
The health of SSDAC1 and SSDAC2 units are continuously monitored and proved in vital relay
drive circuits.
The vital relay drive is available independentlyat either end of the section from SSDAC1 and
SSDAC2 units.

41. SOLID STATE INTERLOCKING
Solid State Interlocking (SSI) is Signaling System to select and operate the routes in station for
guiding the movement of the trains. The system replaces the conventional Route Relay
Interlocking. The system is designed with “2 out of 2” Microprocessor with hot standby. The
system has software redundancy.
The operator panel is used to control and command and display the status of SSI.
FEATURES:
· System capacity: 450 Input, 72 Output.
· Dual Microprocessor Based (2 out of 2) Fail-safe design.
· Hot standby for High System Availability.
· On Line self-diagnostic facility.
· Data Logging with Time Stamping of all SSI Inputs and Outputs for Off-line analysis.
· Opto Isolated Inputs and Outputs.
· Modular design for easy maintenance and expansion.

42. SOLAR POWEREDRAILWAY LEVEL CROSSING RADIO
WARNING SYSTEM
(SOLARGUARD ™)
CEL has developed this system, in association with Research, Designs and Standards
Organization (RDSO) for providing early warning of a train / locomotive approaching unmanned
level crossing, to the people and road traffic crossing the Railway line.
SYSTEM OPERATION:
A track device actuated solar powered VHF transmitter located 3-4 Kms, from the level crossing
(i.e. Far End) sends a coded radio signal towards the level crossing when an approaching train
crosses the Far End. The radio signal is received by solar powered receiver located at the level
crossing (Gate End) which after decoding the signal actuates an Audio- Visual Alarm for
forewarning the traffic. The system is ideal for remote railway level crossings. The ruggedized
system is under extensive field trials.

43. SELF EVALUATION
This 6 weeksIndustrial Training has ledme to understand the various designing,assembling and
the manufacturing processes of equipments in the industry, CEL.
It has also enhanced my knowledge about the functioning and management of an industry, which
I am sure, will be beneficial to me in my career.
AKSHAY DHAKA
ECE-B1
GLA UNIVERSITY
MATHURA